Particulate Catch Basin for Condensate Drain Line

ABSTRACT

A particulate catch basin device for a condensate drain line used with an air conditioning system is described. The device includes a detachable water container in which solid particulates are captured. The detachable water container is connected to a head apparatus to which a condensate water line is attached. Water inside the detachable water container operates as a trap to capture particulates contained in condensate water entering into the device from an air handler through the condensate water line. Water, with the particulates removed by their capture within the detachable water container, flows out of the device through a connected drain pipe. A maximum water height within the detachable water container and head should not exceed a point that is lower than a lowest point of entry into the drain pipe. The device can include transparent materials to facilitate monitoring of the accumulation of particulates within the detachable water container.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part application of U.S. nonprovisional patent application Ser. No. 15/684,768 filed on Aug. 23, 2017. The foregoing applications are incorporated in their entirety herein by reference.

FIELD OF THE INVENTION

The invention relates to air conditioner systems. More particularly, the invention relates to a particulate catch basin for a condensate drain line of an air conditioner system.

BACKGROUND

Conventional air conditioner systems (also called an air conditioner, an air conditioning system, and a HVAC) include a trap pipe as part of a drainage system to allow condensate water to flow out of the system through a drain line and to prevent air from moving into or out of the system during operation through the drain line. Trap pipes (also called traps or P-traps) are prone to clogging as particulates in the condensate water exiting the air handler collect within the trap pipe. P-traps are one of the main causes of drain line clogging, which causes the breakdown of air conditioning systems. Once the trap pipe becomes clogged, the system ceases to operate and does not cool the air. Condensate water can also back up within the system and flow out of the air handler damaging walls, flooring, or other items.

A need exists for a device that captures and collects particulates contained in condensate water exiting an air handler so that an air conditioner system's drain line does not become clogged. Another need exists for a device that captures and collects particulates contained in condensate water exiting an air handler, wherein the device is easily cleanable and the captured particulates easily removed. Still another need exists for a device that captures and collects particulates contained in condensate water exiting an air handler, wherein the captured particulates are visible within the device so that it may be cleaned before it becomes filled with particulates. Yet another need exists for a device that allows condensate water to flow out of an air conditioner system through a drain line and that prevents air from moving into or out of the air conditioner system during operation through the drain line while also avoiding use of one or more P-traps, which are prone to clogging that causes breakdown of the system.

SUMMARY

The invention relates to a particulate catch basin device for a condensate drain line used with an air conditioning system is described. The device includes a detachable water container in which solid particulates are captured. The detachable water container is connected to a head apparatus to which a condensate water line is attached. Water inside the detachable water container operates as a trap to capture particulates contained in condensate water entering into the device from an air handler through the condensate water line. Water, with the particulates removed by their capture within the detachable water container, flows out of the device through a connected drain pipe. A maximum water height within the detachable water container and head should not exceed a point that is lower than a lowest point of entry into the drain pipe. The device can include transparent materials to facilitate monitoring of the accumulation of particulates within the detachable water container.

The particulate catch basin device provides an advantage over conventional air conditioning systems by capturing and collecting particulates contained in condensate water exiting an air handler so that an air conditioner system's drain line does not become clogged. The particulate catch basin device also provides an advantage over conventional air conditioning systems by capturing and collecting particulates contained in condensate water exiting an air handler in a way that the device is easily cleanable and the captured particulates easily removed. The particulate catch basin device provides another advantage by capturing and collecting particulates contained in condensate water exiting an air handler so that the captured particulates are visible within the device, thereby allowing it to be cleaned before it becomes filled with particulates.

The particulate catch basin device also provides an advantage over conventional air conditioning systems by replacing conventional P-traps, which are prone to clogging that causes the air conditioning system to break down and fail to operate. The particulate catch basin device and methods related to its use allow condensate water to flow out of an air conditioner system through a drain line without the risk of clogging by particulates and prevent air from moving into or out of the air conditioner system during operation through the drain line.

Accordingly, the invention features a particulate catch basin device for capturing particulates flowing through a condensate drain line of an air conditioner system. The device includes a head apparatus, a container, a condensate line, and a drain line. The head apparatus features a top portion, a bottom portion, and a side wall, wherein the side wall includes an inlet aperture and an outlet aperture. Particulates are captured from a condensate inside the container. A top open portion of the container is detachably connectable to the bottom portion of the head apparatus. The condensate line connects an air handler to the head apparatus at the inlet aperture. Condensate water from the air handler flows through the condensate line and into the head apparatus. The condensate line features an open end through which condensate water exits the condensate line and flows into the container. A water level inside the container is a sufficient height to prevent air from entering into the condensate line from the container. The drain line connects to the outlet aperture to allow condensate water to exit the container.

In another aspect, the invention can feature one or more parts of the particulate catch basin device are constructed from a transparent material.

In another aspect, the invention can feature the condensate line having a drain portion that includes the open end. The drain portion is oriented downward inside the container so that the open end is configured at a first position that is lower than a second position that is a lowest point within an interior of the condensate line where the condensate line connects to the inlet aperture.

In another aspect, the invention can feature a drain element being connected to the open end of the condensate line. The drain element includes a connecting end that connects to the open end of the condensate line and a drain element open end that allows condensate water to flow out of the drain element and into the container.

In another aspect, the invention can feature the container includes an overflow trough attached to an outer surface of the container to catch condensate water when the container is detached from the head apparatus.

In another aspect, the invention can feature condensate water from the air handler entering the container through the head apparatus from the condensate line and collecting within the container so that a maximum water level within the container is near a lower inner surface of the drain pipe so that excess condensate water flows out of the drain pipe.

In another aspect, the invention can feature the bottom portion of the head apparatus being attached to a top portion of the container by: (i) screwing the container onto the head apparatus, wherein the bottom portion of the head apparatus includes threading and the top portion of the container also includes threading so that the container is attachable to the bottom portion of the head apparatus by screwing the top portion of the container over or into the bottom portion of the head apparatus; or (ii) clipping the container onto the head apparatus using one or more clips, clamps, snaps, latches, a combination of two or more of the foregoing, or any other suitable connection apparatuses

In another aspect, the invention can feature an interior of the container being divided into a first section and a second section by a wall. The wall does not extend to a bottom of the container. The condensate line enters the head apparatus at the first section and the drain line exits the head apparatus at the second section.

In another aspect, the invention can feature the head apparatus including means for holding a chemical drain cleaner that is released into the condensate water inside the container when the water level within the container rises so that the condensate water contacts the chemical drain cleaner within the means for holding.

In another aspect, the invention can feature the condensate line being part of an existing air conditioner system and the head apparatus being installable so as to be connected to the existing air conditioner system.

The invention also features a particulate catch basin device for capturing particulates flowing through a condensate drain line of an air conditioner system, wherein the device includes a head apparatus, a container in which particulates are captured from a condensate, a condensate line, and a drain line. The head apparatus includes a top portion, a bottom portion, and a side wall. The side wall features an inlet aperture and an outlet aperture. A top open portion of the container is detachably connectable to the bottom portion of the head apparatus. An interior of the container is divided into a first section and a second section by a wall. The wall does not extend to a bottom of the container. The condensate line enters the head apparatus at the first section and the drain line exits the head apparatus at the second section. The condensate line connects an air handler to the head apparatus at the inlet aperture, and condensate water from the air handler flows through the condensate line and into the head apparatus. The condensate line features an open end through which condensate water exits the condensate line and flows into the container. A water level inside the container is a sufficient height to prevent air from entering into the condensate line from the container. The drain line connects to the outlet aperture to allow condensate water to exit the container.

In another aspect, the invention can feature the condensate line having a drain portion that includes the open end. The drain portion is oriented downward inside the container so that the open end is configured at a first position that is lower than a second position that is a lowest point within an interior of the condensate line where the condensate line connects to the inlet aperture.

In another aspect, the invention can feature a drain element being connected to the open end of the condensate line. The drain element includes a connecting end that connects to the open end of the condensate line and a drain element open end that allows condensate water to flow out of the drain element and into the container.

In another aspect, the invention can feature condensate water from the air handler entering the container through the head apparatus from the condensate line and collecting within the container so that a maximum water level within the container is near a lower inner surface of the drain pipe so that excess condensate water flows out of the drain pipe.

In another aspect, the invention can feature the head apparatus including means for holding a chemical drain cleaner that is released into the condensate water inside the container when the water level within the container rises so that the condensate water contacts the chemical drain cleaner within the means for holding.

In another aspect, the invention can feature the condensate line being part of an existing air conditioner system and the head apparatus being installable so as to be connected to the existing air conditioner system.

A method of the invention can be used for capturing and removing particulates in a flow of condensate water from an air handler of an air conditioner system. The method includes the steps of: (a) connecting a particulate catch basin device to a condensate line attached to an air handler, wherein the particulate catch basin device features: a head apparatus including a top portion, a bottom portion, and a side wall, wherein the side wall includes an inlet aperture and an outlet aperture; a container in which particulates are captured from a condensate, wherein a top open portion of the container is detachably connectable to the bottom portion of the head apparatus; the condensate line connecting an air handler to the head apparatus at the inlet aperture, wherein condensate water from the air handler flows through the condensate line and into the head apparatus, wherein the condensate line includes an open end through which condensate water exits the condensate line and flows into the container, and wherein a water level inside the container is a sufficient height to prevent air from entering into the condensate line from the container; and a drain line connected to the outlet aperture for allowing condensate water to exit the container; (b) capturing particulates in condensate water flowing from the air handler through the condensate line within the container of the particulate catch basin device; and (c) allowing condensate water with particulates removed to flow out of the particulate catch basin device through the drain pipe.

Another method of the invention includes the steps of: (d) detaching the container from the head apparatus and emptying the container of particulates captured within the container from the condensate water; and (e) reattaching the container to the head apparatus.

Another method of the invention features step (a) of the method further including the step of: (f) connecting a drain element to the open end of the condensate line; wherein the drain element includes a connecting end that connects to the open end of the condensate line and a drain element open end that allows condensate water to flow out of the drain element and into the container. The drain element open end is positioned lower than a maximum water level inside the container.

Another method of the invention features an interior of the container being divided into a first section and a second section by a wall. The wall does not extend to a bottom of the container so that an opening exists at the bottom of the container between the first section and the second section. The condensate line enters the head apparatus at the first section so that particulates are forced downward by gravity and by flow of the condensate water toward the bottom of the container where they collect. The condensate water flows through the opening from the first section into the second section, and condensate water exits through the drain line, which exits the head apparatus at the second section.

Unless otherwise defined, all technical terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, suitable methods and materials are described below. All publications, patent applications, patents and other references mentioned herein are incorporated by reference in their entirety. In the case of conflict, the present specification, including definitions will control.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective side view of a particulate catch basin device for capturing particulates flowing through a condensate drain line of an air conditioner system.

FIG. 2 is a side elevation view of a head apparatus of the device of FIG. 1.

FIG. 3 is a top plan view of the head apparatus of FIG. 2.

FIG. 4 is a bottom plan view of the head apparatus of FIG. 2.

FIG. 5 is a perspective side view of a container of the device of FIG. 1.

FIG. 6 is a sectional side elevation view of the device of FIG. 1.

FIG. 7 is a sectional side elevation view of another embodiment of a particulate catch basin device for capturing particulates flowing through a condensate drain line of an air conditioner system, wherein the device includes a wall inside a container.

FIG. 8 is a sectional top plan view of the device of FIG. 7.

FIG. 9 is a sectional side elevation view of another embodiment of a particulate catch basin device for capturing particulates flowing through a condensate drain line of an air conditioner system, wherein the device includes a wall inside a container and a means for holding a chemical drain cleaner in a head apparatus of the device.

DETAILED DESCRIPTION

The present invention is best understood by reference to the detailed drawings and description set forth herein. Embodiments of the invention are discussed below with reference to the drawings; however, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes as the invention extends beyond these limited embodiments. For example, in light of the teachings of the present invention, those skilled in the art will recognize a multiplicity of alternate and suitable approaches, depending upon the needs of the particular application, to implement the functionality of any given detail described herein beyond the particular implementation choices in the following embodiments described and shown. That is, numerous modifications and variations of the invention may exist that are too numerous to be listed but that all fit within the scope of the invention. Also, singular words should be read as plural and vice versa and masculine as feminine and vice versa, where appropriate, and alternative embodiments do not necessarily imply that the two are mutually exclusive.

The present invention should not be limited to the particular methodology, compounds, materials, manufacturing techniques, uses, and applications, described herein, as these may vary. The terminology used herein is used for the purpose of describing particular embodiments only, and is not intended to limit the scope of the present invention. As used herein and in the appended claims, the singular forms “a,” “an,” and “the” include the plural reference unless the context clearly dictates otherwise. Thus, for example, a reference to “an element” is a reference to one or more elements and includes equivalents thereof known to those skilled in the art. Similarly, for another example, a reference to “a step” or “a means” may be a reference to one or more steps or means and may include sub-steps and subservient means.

All conjunctions used herein are to be understood in the most inclusive sense possible. Thus, a group of items linked with the conjunction “and” should not be read as requiring that each and every one of those items be present in the grouping, but rather should be read as “and/or” unless expressly stated otherwise. Similarly, a group of items linked with the conjunction “or” should not be read as requiring mutual exclusivity among that group, but rather should be read as “and/or” unless expressly stated otherwise. Structures described herein are to be understood also to refer to functional equivalents of such structures. Language that may be construed to express approximation should be so understood unless the context clearly dictates otherwise.

Unless otherwise defined, all terms (including technical and scientific terms) are to be given their ordinary and customary meaning to a person of ordinary skill in the art, and are not to be limited to a special or customized meaning unless expressly so defined herein.

Terms and phrases used in this application, and variations thereof, especially in the appended claims, unless otherwise expressly stated, should be construed as open ended as opposed to limiting. As examples of the foregoing, the term “including” should be read to mean “including, without limitation,” “including but not limited to,” or the like; the term “having” should be interpreted as “having at least”; the term “includes” should be interpreted as “includes but is not limited to”; the term “example” is used to provide exemplary instances of the item in discussion, not an exhaustive or limiting list thereof; and use of terms like “preferably,” “preferred,” “desired,” “desirable,” or “exemplary” and words of similar meaning should not be understood as implying that certain features are critical, essential, or even important to the structure or function of the invention, but instead as merely intended to highlight alternative or additional features that may or may not be utilized in a particular embodiment of the invention.

Those skilled in the art will also understand that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations; however, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to embodiments containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C” is used, in general, such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.).

All numbers expressing dimensions, quantities of ingredients, reaction conditions, and so forth used in the specification are to be understood as being modified in all instances by the term “about” unless expressly stated otherwise. Accordingly, unless indicated to the contrary, the numerical parameters set forth herein are approximations that may vary depending upon the desired properties sought to be obtained.

The invention provides a particulate catch basin device 10 for capturing particulates flowing through a condensate drain line of an air conditioner system. The device 10 can be incorporated as a part of a new air conditioner system or can be installed in communication with a drain line of an existing air conditioner system. By installing the device 10 as part of a new or existing air conditioner system, a P-trap of an air conditioning system's conventional drainage system is no longer needed. The device 10 includes a head apparatus 12 having a top portion 12 a, a bottom portion 12 b, and a side wall 12 c. The top portion 12 a of the head apparatus 12 includes a top side 22 and a bottom side 24. A top aperture 26 extends through the head apparatus 12 from its top side 22 to its bottom side 24. A side aperture 28 extends from an outer surface 30 of the side wall 12 c through an inner surface 32 of the side wall into an interior space 34 of the head apparatus 12. The device 10 also includes a container 14 in which particulates are captured from a condensate, i.e., condensate water. A top portion 14 a of the container 14 is detachably connectable to the bottom portion 12 b of the head apparatus 12. The top portion 14 a of the container 14 includes an opening 14 d that communicates with the interior space 34 of the head apparatus 12. The device 10 further includes a condensate line 16 connecting an air handler to the head apparatus 12 at the top aperture 26. The condensate line 16 and air handler can be part of a new air conditioning system of which the device 10 is a component, or alternatively, they can be part of an existing air conditioning system in which the device 10 is installed to retrofit the existing air conditioning system thereby improving its operation. The device 10 also includes a drain line 18 connected to the side aperture 28 for allowing condensate water to exit the container 14. Condensate water from the air handler flows through the condensate line 16 and into the head apparatus 12 and particulates are trapped in the container 14 that is attached to the head apparatus.

In one embodiment, the head apparatus 12 can be constructed from a transparent material. In another embodiment, the container 14 can be constructed from a transparent material. In another embodiment, one or both of the condensate line 16 and the drain line 18 can be constructed from a transparent material. In exemplary embodiments, the head apparatus 12, container 14, and drain line 18 may all be constructed from transparent materials. The transparency of the material used to construct these parts of the device 10 allows for viewing of a level of accumulated particulates within the container 14 and for clogging of the drain line 18. In still another embodiment, the condensate line 16 can be constructed from a transparent material.

In one exemplary embodiment, the container 14 includes an overflow trough 20 attached to an outer surface 14 b of the container to catch condensate water when the container is detached from the head apparatus 12. For example, if the container 14 is nearly filled with condensate water and particulates, the water level within an interior space 14 c of the container will be high and water may spill out of the container during its separation from the head apparatus 12. In exemplary embodiments, the container 14 is cylindrical in shape and the overflow trough 20 is annular in shape. In other embodiments, the container 14 and overflow trough 20 may have other non-circular shapes.

Condensate water from the air handler enters the container through the head apparatus 12 from the condensate line 16 that exits the air handler. The condensate water collects within the container 14 so that a maximum water level within the container is near a lower inner surface 18 a of the drain pipe 18 so that excess condensate water flows out of the drain pipe. Once water within the container 14 rises to the level of the lower inner surface 18 a of the drain pipe 18, the water flows into and through the drain pipe to exit the air conditioner system.

In exemplary embodiments, the bottom portion 12 b of the head apparatus 12 includes threading and the top portion 14 a of the container 14 also includes threading so that the container is attachable to the bottom portion 12 b of the head apparatus by screwing the top portion of the container over or into the bottom portion of the head apparatus. In other embodiments, the container 14 may be attached to the head apparatus 12 by other means such as clips, clamps, snaps, latches, or similar connection apparatuses.

The condensate line 16 can be part of an existing air conditioner system and the head apparatus 12 is installable so as to be connected to the existing air conditioner system at the connection of the condensate line to the head apparatus.

The invention also includes a method for capturing and removing particulates in a flow of condensate water from an air handler of an air conditioner system. The method uses the particulate catch basin devices described herein above. In one step of the method, a particulate catch basin device is connected to a condensate line attached to an air handler. In the next step of the method, particulates in condensate water flowing from the air handler through the condensate line are captured within the container of the particulate catch basin device. In the next step of the method, condensate water with particulates removed is allowed to flow out of the particulate catch basin device through the drain pipe.

In another step of the method, the container is removed from the head apparatus and the container is emptied and cleaned of particulates captured within the container from the condensate water. In a related step, when the container is detached from the head apparatus, condensate water that may spill from the container is captured in an overflow trough attached to an outer surface of the container. The container is reattached to the head apparatus after removal and cleaning.

In another step of method, the amount of particulates collected within a bottom of the container is determined without detaching the container from the head apparatus by viewing the particulate level through the container wall, wherein the container is constructed from a transparent material. In another embodiment of this step, the head apparatus may be constructed from a transparent material so that the particulate level within the container may be determined visibly by looking through the head apparatus.

In an alternative step of the method, the condensate line can be part of an existing air conditioner system and the head apparatus is installable so as to be connected to the existing air conditioner system to enable retrofitting of old air conditioner systems to improve performance by preventing clogging of drain lines.

The invention also provides a particulate catch basin device 10, such as those shown in FIGS. 7-9, for capturing particulates flowing through a condensate drain line of an air conditioner system. In these embodiments, the condensate line 16 can be positioned on and communicatively connected to the side wall 12 c of the head apparatus 12 as shown in FIGS. 7, 8, and 9 (rather to the top portion 12 a of the head apparatus as in the embodiment of FIG. 1). The particulate catch basin device 10 includes a head apparatus 12, a container 14, a condensate line 16, and a drain line 18. One or more parts of the particulate catch basin device 10 (or one or more portions of such parts) may be constructed from a transparent material. In exemplary embodiments, the head apparatus 12, the container 14, or both are constructed from a transparent material.

The head apparatus 12 features a top portion 12 a, a bottom portion 12 b, and a side wall 12 c (or side walls), wherein the side wall includes an inlet aperture 36 and an outlet aperture 38. The head apparatus 12 defines an interior space 34, wherein the bottom portion of the head apparatus is formed by a bottom of the side wall 12 c and is open-ended. The interior space 34 extends into an interior space 14 c of the container 14 when the head apparatus 12 and container are connected to one another. The head apparatus 12 may include a lid 40. In one embodiment, the lid 40 may be of a type that screws off of the top portion 12 a of the head apparatus 12. In another embodiment, the lid 40 may be of a type that flips open from the top portion 12 a of the head apparatus 12 to provide access to the interior space 34.

In some embodiments, as shown in FIG. 9, the head apparatus 12 may include means for holding 42 a chemical drain cleaner 44 that is released into the condensate water inside the container 14 when the water level within the container rises so that the condensate water contacts the chemical drain cleaner within the means for holding. Once the condensate water contacts the chemical drain cleaner 44 within the means for holding 42, the chemical drain cleaner dissolves, enters into the condensate water inside the container 14, and flows through eventually reaching the drain line 18, which the chemical drain cleaner then unclogs. In one embodiment, the means for holding 42 can be a chamber formed inside an interior top portion of the head apparatus 12. The chamber may include a bottom wall that includes one or more apertures that permit the entry of condensate water inside the chamber when the water level rises inside the head apparatus. In another embodiment, the means for holding 42 can be two, three, four, or more retaining elements 42 (as shown in FIG. 9) that protrude from an interior surface 32 of the side wall or side walls 12 c of the head apparatus 12 so that the chemical drain cleaner 44 (which may be in solid form) can be positioned above and resting upon a top surface of the retaining elements 42. In another embodiment, the means for holding 42 can be a screen or mesh that is removably attached to an interior surface 32 of the side wall or side walls 12 c of the head apparatus 12 so that the chemical drain cleaner 44 can be positioned above and resting upon a top surface of the screen or mesh, which allows condensate water to reach the chemical drain cleaner when the water level rises inside the head apparatus. Examples of chemical drain cleaners 42 include compositions containing bleach (e.g., sodium hypochlorite in solution), lye (e.g., sodium hydroxide or potassium hydroxide), ammonia, an acid (e.g., sulfuric acid), or combinations of two or more of the foregoing (where such combinations can be made safely).

Particulates (e.g., dirt and debris) are captured from a condensate (i.e., the condensate water) inside the container 14. A top open portion 14 a of the container 14 is detachably connectable to the bottom portion 12 b of the head apparatus 12. The container 14 serves a purpose similar to a P-trap in other conventional systems in that the container 14 not only captures particulates in its bottom but also prevents outside air (typically warmer air during warmer months and in warmer climate areas) from being pulled by the air handler through the drain line 18 and condensate line 16 back into the air handler. In some embodiments, the container 14 includes an overflow trough 20 attached to an outer surface 14 b of the container 14 to catch condensate water when the container is detached from the head apparatus 12. FIG. 7 includes arrows that indicate the flow of condensate water through head apparatus 12 and the container 14.

The container 14 may be attached to the head apparatus 12 by threading or by clips, clamps, snaps, latches, or similar connection apparatuses as shown in FIG. 7.

In an exemplary embodiment, the container 14 includes a wall 46 located within an interior space 14 c of the container. In exemplary embodiments, the wall 46 is sufficiently sized to so that its top end 46 a extends above the top portion 14 a of the container 14 and into the interior space 34 of the head apparatus 12 when the head apparatus and container are joined together. The wall 46 divides the interior space 14 c of the container 14 and the interior space 34 of the head apparatus 12 into a first section 48 and a second section 50. This dividing wall 46 does not extend to a bottom 14 e of the container 14, but leaves an opening 52 near the bottom 14 e of the container so that condensate water may flow from the first section 48 into the second section 50 where it eventually exits the container through the drain line 18. The dividing wall 46 can be vertically oriented within the container 14 or may be angled. For example, a top portion 46 a of the dividing wall 46 could be angled either toward or away from the condensate line 16. The dividing wall 46 can be planar or may include one or more sections that angle away from a vertical plane of the remainder of the dividing wall. For example, the dividing wall 46 could include a generally planar, vertically oriented bottom portion and an angled top portion that is connected to a top end of the bottom portion and is oriented at an angle either toward or away from the condensate line 16.

Even if the container 14 is not cleaned so that particulates accumulated within it are not removed, the device is designed in such a way that the particulates and condensate water will continue to flow through the device 10 and will exit through the drain line 18 so that the device 10 improves performance and prevents breakdown of an air conditioner system. In this way, the device 10 differs from a conventional air conditioning system having a P-trap in which the particulates eventually cause a blockage or clogging that prevents condensate water from passing through the P-trap and out of the drain line, thereby causing a mechanical failure of the air conditioner system. If the device 10 still becomes clogged (for example, in its drain line 18), in embodiments such as those shown in FIG. 9 that include a means for holding 42 and a chemical drain cleaner 44, the condensate water level will rise within the container 14 and into the head apparatus 12. If the water level rises high enough, the condensate water will contact the chemical drain cleaner 44 held by the means for holding 42. The chemical drain cleaner 44 is dissolved by the condensate water so that its released from the means for holding 42 into the condensate water to clear the clog so that the condensate water may continue flowing through the device 10 and out of the drain line 18.

In the foregoing embodiment, the condensate line 16 enters the head apparatus 12 at the first section 48 and the drain line 18 exits the head apparatus at the second section 50. The condensate line 16 (or a drain element or drain portion connected thereto) may be oriented so that its open end opens into the first section 48 (which is the closest compartment to the open end) and is at a height at which the open end is beneath the water level inside the container 14. Particulates in the condensate water that enter into the container 14 via the condensate line 16 are forced downward (by the flow of the condensate water, gravity, or both) so that they collect in the bottom 14 e of the container 14 rather than floating and flowing into the drain line 18. Any particulates that do not sink to the bottom 14 e of the container 14 but continue to float will be prevented by the dividing wall 46 from entering the drain line 18 by floating within the first section 48 adjacent to the condensate line 16 instead of floating into the second section 50, which is adjacent to the drain line 18.

The condensate line 16 connects an air handler (not shown in the drawings) to the head apparatus 12 at the inlet aperture 36. Condensate water from the air handler flows through the condensate line 16 and into the interior space 34 of the head apparatus 12. The condensate line 16 features an open end through which condensate water exits the condensate line and flows into the head apparatus 12 and container 14. A water level inside the interior spaces 34 and 14 c of the connected head apparatus 12 and container 14 is a sufficient height to prevent air from entering into the condensate line 16 from the head apparatus or container.

In an exemplary embodiment, as shown in FIG. 7, the particulate catch basin device 10 may further include a drain element 54 that is connected to the open end 16 a of the condensate line 16. The drain element 54 includes a connecting end 54 a that connects to the open end 16 a of the condensate line 16 and a drain element open end 54 b that allows condensate water to flow out of the drain element 54 and into the container 14. The connecting end 54 a of the drain element 54 can be connected to the condensate line 16 where the open end 16 a of the condensate line connects to the head apparatus 12, or the open end 16 a of condensate line 16 may extend into the interior space 34 of the head apparatus 12 and the connecting end 54 a of the drain element 54 may be connected to the open end 16 a of the condensate line 16 within the interior space 34 of the head apparatus 12. The connecting end 54 a of the drain element 54 can be oriented generally horizontally within the interior space 34 of the head apparatus 12. The drain element open end 54 b of the drain element 54 can be generally vertical and pointed downward toward the bottom 14 e of the container 14. Like the condensate line 16 and the drain line 18, the drain element 54 can be a hollow pipe or tube that includes the generally horizontal first end (i.e., the connecting end 54 a), the generally vertical second end (i.e., the drain element open end 54 b), and a curved portion connecting them, as shown in FIG. 7. In another embodiment, the drain element 54 can be a hollow pipe or tube that includes the generally horizontal first end 54 a, the generally vertical second end 54 b, and an elbow joint or L-shaped portion connecting them.

In another embodiment, the drain element 54 may be an attached component of the head apparatus 12. The drain element 54 can be located inside the interior space 34 of the head apparatus 12. The drain element 54 can be permanently or removably attached around the inlet aperture 36 of the head apparatus 12 inside the interior space 34 of the head apparatus so that the open end 16 a of the condensate line 16 connects to the connecting end 54 a of the drain element that is generally horizontal. The drain element open end 54 b of the drain element 54 can be generally vertical and pointed downward toward the bottom 14 e of the container 14.

In another embodiment shown in FIGS. 7 and 9, the drain element 54 may include a pipe 56 that connects to the drain element open end 54 b. The pipe 56 includes a first end that connects to the drain element open end 54 b and an open end. Condensate water flows through the condensate line 16 into the drain element 54 and out of the pipe 56 into the void inside the head apparatus 12 and container 14. The pipe 56 extends through the void above the condensate water line within the connected head apparatus and container. The open end of the pipe 56 terminates above, at, or below the condensate water line, which is the surface of the condensate water that has accumulated inside the void of the connected head apparatus and container. In exemplary embodiments, the open end of the pipe 56 may extend just below the surface of the condensate water line.

In another embodiment, the condensate line 16 may have a drain portion that includes the open end. The drain portion can be a unitary part of the condensate line permanently attached and forming the open end of the condensate line. The drain portion is oriented downward inside the container so that the open end is configured at a first position that is lower than a second position that is a lowest point within an interior of the condensate line where the condensate line connects to the inlet aperture.

In the foregoing embodiments, by positioning the open end 16 a or 54 a of the condensate line 16, the drain element 54, or the drain portion of the condensate line below the water level inside the container 14 so that such open end is underwater, the particulate catch basin device 10 operates in similar fashion as a system including a conventional P-trap. As explained elsewhere above, the open end 16 a or 54 a of the condensate line 16, the drain element 54, or the drain portion of the condensate line will curve or otherwise be oriented downward into the first section 48 created by the dividing wall 46 so that particulates downward contained in the condensate water entering the container 14 from the condensate line 16 are forced downward and collect in the bottom 14 e of the container (similar to a P-trap system) rather than floating and flowing into the drain line 18. Without a dividing wall 46, such particulates could merely float across the surface of the condensate water within the container 14 and enter into the drain line 18 causing it to clog, thereby impeding the normal operation of the air conditioner system. Because the open end (e.g., of the condensate line, the drain element, or the drain portion of the condensate line) is underwater, warmer outside air that enters the container 14 through the drain line 18 cannot be pulled through the condensate line 16 back into the air handler, which would interfere with its cooling operation.

The drain line 18 connects to the outlet aperture 38 to allow condensate water to exit the head apparatus 12 and container 14. A bottom inner surface of the drain pipe 18 is located at a position that is lower than a bottom interior surface of the condensate line 16 at its open end 16 a. In other embodiments, the bottom inner surface of the drain pipe 18 may be located at a position that is higher than or at a height that is equal to (meaning vertically parallel to) the bottom interior surface of the condensate line 16 at its open end 16 a.

The particulate catch basin device 10 and its various embodiments described herein can feature the condensate line 16 being part of an existing air conditioner system and the head apparatus 12 being installable so as to be connected to the existing air conditioner system.

Other Embodiments

It is to be understood that while the invention has been described in conjunction with the detailed description thereof, the foregoing description is intended to illustrate and not limit the scope of the invention, which is defined by the scope of the appended claims. Other aspects, advantages, and modifications are within the scope of the following claims. 

What is claimed is
 1. A particulate catch basin device for capturing particulates flowing through a condensate drain line of an air conditioner system, the device comprising: a head apparatus comprising a top portion, a bottom portion, and a side wall, wherein the side wall comprises an inlet aperture and an outlet aperture; a container in which particulates are captured from a condensate, wherein a top open portion of the container is detachably connectable to the bottom portion of the head apparatus; a condensate line connecting an air handler to the head apparatus at the inlet aperture, wherein condensate water from the air handler flows through the condensate line and into the head apparatus, wherein the condensate line comprises an open end through which condensate water exits the condensate line and flows into the container, and wherein a water level inside the container is a sufficient height to prevent air from entering into the condensate line from the container; and a drain line connected to the outlet aperture for allowing condensate water to exit the container.
 2. The particulate catch basin device of claim 1, wherein one or more parts of the particulate catch basin device are constructed from a transparent material.
 3. The particulate catch basin device of claim 1, wherein the condensate line comprises a drain portion that comprises the open end; and wherein the drain portion is oriented downward inside the container so that the open end is configured at a first position that is lower than a second position that is a lowest point within an interior of the condensate line where the condensate line connects to the inlet aperture.
 4. The particulate catch basin device of claim 1, wherein a drain element is connected to the open end of the condensate line; and wherein the drain element comprises a connecting end that connects to the open end of the condensate line and a drain element open end that allows condensate water to flow out of the drain element and into the container.
 5. The particulate catch basin device of claim 1, wherein the container comprises an overflow trough attached to an outer surface of the container to catch condensate water when the container is detached from the head apparatus.
 6. The particulate catch basin device of claim 1, wherein condensate water from the air handler enters the container through the head apparatus from the condensate line and collects within the container so that a maximum water level within the container is near a lower inner surface of the drain pipe so that excess condensate water flows out of the drain pipe.
 7. The particulate catch basin device of claim 1, wherein the bottom portion of the head apparatus is attached to a top portion of the container by: (i) screwing the container onto the head apparatus, wherein the bottom portion of the head apparatus comprises threading and the top portion of the container also comprises threading so that the container is attachable to the bottom portion of the head apparatus by screwing the top portion of the container over or into the bottom portion of the head apparatus; or (ii) clipping the container onto the head apparatus using one or more clips, clamps, snaps, latches, a combination of two or more of the foregoing, or any other suitable connection apparatuses.
 8. The particulate catch basin device of claim 1, wherein an interior of the container is divided into a first section and a second section by a wall; wherein the wall does not extend to a bottom of the container; and wherein the condensate line enters the head apparatus at the first section and the drain line exits the head apparatus at the second section.
 9. The particulate catch basin device of claim 1, wherein the head apparatus comprises means for holding a chemical drain cleaner that is released into the condensate water inside the container when the water level within the container rises so that the condensate water contacts the chemical drain cleaner within the means for holding.
 10. The particulate catch basin device of claim 1, wherein the condensate line is part of an existing air conditioner system and the head apparatus is installable so as to be connected to the existing air conditioner system.
 11. A particulate catch basin device for capturing particulates flowing through a condensate drain line of an air conditioner system, the device comprising: a head apparatus comprising a top portion, a bottom portion, and a side wall, wherein the side wall comprises an inlet aperture and an outlet aperture; a container in which particulates are captured from a condensate, wherein a top open portion of the container is detachably connectable to the bottom portion of the head apparatus, wherein an interior of the container is divided into a first section and a second section by a wall, wherein the wall does not extend to a bottom of the container, and wherein the condensate line enters the head apparatus at the first section and the drain line exits the head apparatus at the second section; a condensate line connecting an air handler to the head apparatus at the inlet aperture, wherein condensate water from the air handler flows through the condensate line and into the head apparatus, wherein the condensate line comprises an open end through which condensate water exits the condensate line and flows into the container, and wherein a water level inside the container is a sufficient height to prevent air from entering into the condensate line from the container; and a drain line connected to the outlet aperture for allowing condensate water to exit the container.
 12. The particulate catch basin device of claim 11, wherein the condensate line comprises a drain portion that comprises the open end, wherein the drain portion is oriented downward inside the container so that the open end is configured at a first position that is lower than a second position that is a lowest point within an interior of the condensate line where the condensate line connects to the inlet aperture.
 13. The particulate catch basin device of claim 11, wherein a drain element is connected to the open end of the condensate line; wherein the drain element comprises a connecting end that connects to the open end of the condensate line and a drain element open end that allows condensate water to flow out of the drain element and into the container.
 14. The particulate catch basin device of claim 11, wherein condensate water from the air handler enters the container through the head apparatus from the condensate line and collects within the container so that a maximum water level within the container is near a lower inner surface of the drain pipe so that excess condensate water flows out of the drain pipe.
 15. The particulate catch basin device of claim 11, wherein the head apparatus comprises means for holding a chemical drain cleaner that is released into the condensate water inside the container when the water level within the container rises so that the condensate water contacts the chemical drain cleaner within the means for holding.
 16. The particulate catch basin device of claim 1, wherein the condensate line is part of an existing air conditioner system and the head apparatus is installable so as to be connected to the existing air conditioner system.
 17. A method for capturing and removing particulates in a flow of condensate water from an air handler of an air conditioner system, the method comprising the steps of: (a) connecting a particulate catch basin device to a condensate line attached to an air handler, wherein the particulate catch basin device comprises: a head apparatus comprising a top portion, a bottom portion, and a side wall, wherein the side wall comprises an inlet aperture and an outlet aperture; a container in which particulates are captured from a condensate, wherein a top open portion of the container is detachably connectable to the bottom portion of the head apparatus; the condensate line connecting an air handler to the head apparatus at the inlet aperture, wherein condensate water from the air handler flows through the condensate line and into the head apparatus, wherein the condensate line comprises an open end through which condensate water exits the condensate line and flows into the container, and wherein a water level inside the container is a sufficient height to prevent air from entering into the condensate line from the container; and a drain line connected to the outlet aperture for allowing condensate water to exit the container; (b) capturing particulates in condensate water flowing from the air handler through the condensate line within the container of the particulate catch basin device; and (c) allowing condensate water with particulates removed to flow out of the particulate catch basin device through the drain pipe.
 18. The method of claim 17, further comprising the steps of: (d) detaching the container from the head apparatus and emptying the container of particulates captured within the container from the condensate water; and (e) reattaching the container to the head apparatus.
 19. The method of claim 17, wherein step (a) of the method further comprises the step of: (f) connecting a drain element to the open end of the condensate line; wherein the drain element comprises a connecting end that connects to the open end of the condensate line and a drain element open end that allows condensate water to flow out of the drain element and into the container; and wherein the drain element open end is positioned lower than a maximum water level inside the container.
 20. The method of claim 17, wherein an interior of the container is divided into a first section and a second section by a wall; wherein the wall does not extend to a bottom of the container so that an opening exists at the bottom of the container between the first section and the second section; wherein the condensate line enters the head apparatus at the first section so that particulates are forced downward by gravity and by flow of the condensate water toward the bottom of the container where they collect; wherein the condensate water flows through the opening from the first section into the second section; and wherein condensate water exits through the drain line, which exits the head apparatus at the second section. 